1. Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

bensalf's 4 year caferacer build

Discussion in 'XJ Modifications' started by bensalf, Dec 26, 2015.

  1. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    oh!,------I didn't mean the finished article, the whole machine,
    just finished the rear led lights,:oops:
    stu
     
  2. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    other electrical bits are, front and rear led indicator lights, did away with the self cancelling feature, and changed the flasher relay for an electronic one.
    [​IMG]
    [​IMG]
    also fitted ,2, pressure operated brake light switches, these replace the banjo bolts on the front and rear master cylinders

    [​IMG]
    stu
     
    Last edited: Feb 1, 2016
  3. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    next ,onto the brakes. all 3 callipers stripped cleaned and undercoated
    [​IMG]
    cleaned up the groves and pistons with scotchbrite,
    [​IMG]
    [​IMG]
    front master cylinder needed to be rebuilt, sight glass was also cracked, so started to gouge it out
    [​IMG]
    finally got it out, (it put up a fight) ,installed new watch glass crystal, with black silicone
    [​IMG]
    piston stripped out
    [​IMG]
    new rebuild kit obtained and master cylinder rebuilt with new alen screws
    [​IMG]
    stu
     
  4. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    rear master cylinder stripped down.
    [​IMG]
    new repair kit obtained
    [​IMG]
    [​IMG]
    link rod cleaned up.
    [​IMG]
    here's the rebuilt cylinder mounted behind the exhaust hanger
    [​IMG]
    oh,! and there's the card reader, mounted underneath the seat pan. I fitted the end of the reader in a small plastic box, with a hinged lid, to keep the elements out.
    stu
     
    Last edited: Feb 1, 2016
  5. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    next the levers and grips.
    I ditched the original levers , in favour of some adjustable ones, got some grips with the same anodising.
    [​IMG]
    brake lever fitted straight on. but clutch needed some modification to make it fit.
    [​IMG]
    clutch lever now fitted
    [​IMG]
    stu
     
  6. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    I got the bike out from under the covers ,today ,to snap a few more pics, that I did'nt have before
    heres another of the card reader with hinged lid attatched
    [​IMG]

    [​IMG]
    bar end mirrors fitted
    [​IMG]
    stu
     
  7. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    had new stainless steel brake hoses made up, and fitted, here they are bolted to the master cylinder , with the pressure switch banjo bolt, fitted for the brake light
    [​IMG]
    stu
     
  8. mc1oo1

    mc1oo1 Member

    Messages:
    94
    Likes Received:
    26
    Trophy Points:
    18
    Location:
    LB,Ca
    Is that a Kitty Kat on top of the MC??
     
  9. jayrodoh

    jayrodoh YimYam Premium Member

    Messages:
    2,522
    Likes Received:
    1,102
    Trophy Points:
    113
    Location:
    Cleveland
    Don't you hate how those close up flash enabled pics make everything look less than stellar?

    Is there a sight glass in that MC?

    Bike looks great, I'd love to hear how that exhaust sounds, do you have a vid clip by chance?
     
  10. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    -----------------------------------------------------------------------------------
    Is that a Kitty Kat on top of the MC??
    ------------------------------------------------------------------------------------
    ha,ha, its a little mascot lego man, I always make one, painted in the same colours as the bike.
    here he is , mounted in the mirror hole, he's called BELP. --Bar-End-Lookout-Post.
    [​IMG]
    here's another from the green/white Honda C.X. ,on page 3
    [​IMG]
    and here's another ready for painting on the next bike.
    [​IMG]
    stu
     
  11. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    ------------------------------------------------------------------------------------------------------------------------------------------
    Don't you hate how those close up flash enabled pics make everything look less than stellar?
    ------------------------------------------------------------------------------------------------------------------------------------------
    yes, you've noticed on a lot of the close-up's, how they blur out, my pensioner's hands aren't as steady as they used to be.

    -------------------------------------------------------------------------------------------

    Is there a sight glass in that MC?
    ------------------------------------------------------------------------------------------
    yes there is , its hard to tell, but its a watch glass chrystal, cemented in with black silicon sealant, and its filled with fluid.


    ---------------------------------------------------------------------------------------------------------------------------------------

    Bike looks great, I'd love to hear how that exhaust sounds, do you have a vid clip by chance?
    -----------------------------------------------------------------------------------------------------------------------------------------------

    sorry no I don't have a vid, clip , don't think I'd know how to go about doing that, but I was "blown away "with the sound,
    in fact I thought it may be a little too loud for the neighbours.
    so I got some baffeling insulation and set about wrapping the baffles.
    [​IMG]
    wired on some loft insulation first, then the baffleing material
    [​IMG]
    also installed some "penny" washers in the bottom of the baffle to quieten it a bit more, it still sounds awesome though
    stu
     
  12. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    [​IMG]
    stu
     
  13. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    front brake hoses fitted and bled.
    [​IMG]
    stu
     
  14. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    you may be interested in the hose end finishers I made.
    I used some old armoured cable glands that I had, and used the back nuts from them.
    [​IMG]
    I made the breather hose ,from the engine to airbox.
    [​IMG]
    I cut a small rectangular hole in the side of the back nut, just large enough to fit the jubilee clip through
    [​IMG]
    here's the hose in place, on the engine breather

    [​IMG]
    stu
     
  15. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    next onto the tank, which was missing from the original bike, I found a good example at a local breakers, but it needed some internal work, but was complete with fuel tap and level sensor
    [​IMG]
    I made up a makeshift turntable, to spin the tank, with some screws inside,
    it got rid of some loose stuff , but after a while it buggered up my drill chuck
    [​IMG]
    so I had a go at electrolysis.
    I made some blanks for the petcock and fuel level sensor holes
    [​IMG]
    made up a sacrificial anode
    [​IMG]
    solution made up with baking soda and water, and hooked up to battery charger
    [​IMG]
    initial results were promising
    [​IMG]
    [​IMG]
    filtered that lot from the first solution
    then again
    [​IMG]
    and again
    [​IMG]
    and about another dozen times, went through 5 packets of soda,
    in fact the system seemed to be making its own rust ?:confused:
    in the end I made a flexible hose , and attached it to the end of my shot blasting gun, and blasted the inside of the tank,
    using the filler hole and the fuel sender hole
    it looked like I was removing an old tank liner job
    [​IMG]
     
  16. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

    Messages:
    8,854
    Likes Received:
    1,772
    Trophy Points:
    113
    Location:
    At My Computer
    Your "tank spinning fixture" is quite creative....!
     
  17. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    getting better all the time
    [​IMG]
    it ended up pretty good after the blasting, so I rinsed it out with petrol, then swilled it with phosphoric acid.
    dried out ,and all was good.
    sliced off the bottom lugs that the side panels push into.
    [​IMG]
    I got the tank back from the sprayers, and fitted the Monza fuel cap, I'd been itchin to try on.
    I had previously soldered the brass threaded ring, onto the neck of the tank, so I screwed on the new cap.
    [​IMG]
    love it
    [​IMG]
    [​IMG]
    stu
     
  18. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    after I got the tank , seat and front mudguard ,back from the sprayers ,I took the seat to the upholsterers.
    a week later I picked it up, and was very pleased with the results
    [​IMG]
    [​IMG]
    I had the zipped pocket made to house a disc lock
    [​IMG]
    stu
     
  19. quebecois59

    quebecois59 Well-Known Member

    Messages:
    2,285
    Likes Received:
    112
    Trophy Points:
    63
    Location:
    Waterloo, Quebec, Canada
    Isn't it an '83 XJ900 tank?
     
  20. bensalf

    bensalf Well-Known Member

    Messages:
    1,258
    Likes Received:
    249
    Trophy Points:
    63
    Location:
    yorkshire ,england
    SOOOOOOOOOOOOO----------that's pretty much it, apart from having the exhaust down pipes made, the only other things I didn't do myself was the
    tank and seat spraying, and the upholstery.
    all other painting and spraying, and making parts was done by myself.

    so thank you for watching and for all your comments, and questions. if I am able to help any others on here ,then please ask-- just as I have had to do many times
    in the past.
    SO HERES THE FINISHED RESULT

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    stu
     
    Brent NZ and Franz like this.

Share This Page